Wheel assembly including relative movement sensor and related methods

ABSTRACT

A wheel assembly may include an inner rim to be coupled to the hub of the vehicle, and an outer rim surrounding the inner rim. Gas springs may be operatively coupled between the inner rim and the outer rim and permitting relative movement therebetween. The wheel assembly may also include a sensor configured to sense the relative movement between the inner and outer rims.

RELATED APPLICATIONS

The present application claims the priority benefit of provisionalapplication Ser. No. 62/764,138 filed on Jul. 19, 2018, the entirecontents of which are herein incorporated by reference.

TECHNICAL FIELD

The present invention relates to the field of wheels, and, moreparticularly, to a wheel assembly for a vehicle, such as a constructionor mining vehicle, and related methods.

BACKGROUND

A typical wheel may include a rim and tire surrounding the rim. The tiretransfers a load of a vehicle from the axle through the wheel to theground. Tires, for example, those found on most vehicles are pneumatictires. In other words, a typical tire is pneumatically inflated, forexample, with air or other gas, such as nitrogen. More particularly, airis injected into the space between the rim and the inside of the tire toinflate it.

During operation, being pneumatically inflated, a tire absorbs theforces as the vehicle travels over the road surface. The tire andassociated inflation pressure may be selected to absorb the above-notedforces while reducing any deformation. However, in many instances,excessive forces placed on the tire may cause the tire and/or rim todeform, puncture, or blowout. Typical forces also cause tread wear ofthe tire, while excessive forces may also cause rapid tread wear thatmay lead to a shortened lifespan of the tire and decreased structuralintegrity of the wheel.

To address the shortcomings of pneumatic-based wheels, non-pneumaticwheels have been developed. By non-pneumatic, it is meant that air orother gas is not injected to inflate an interior volume of a tire. Oneapproach to a non-pneumatic wheel uses mechanical springs. For example,U.S. Pat. No. 911,975 to Gustafson discloses a spring wheel. Secondaryspokes are arranged in pairs between pairs of main spokes and themembers of each of the secondary spokes therefore pass upon oppositesides of a corresponding pair of intersecting braces. Each of thesecondary spokes includes a pair of telescoping members that arepivotally connected at its outer end to ears formed on the hub andextends at its opposite end into a corresponding member.

U.S. Pat. No. 1,601,518 to Weston discloses a resilient wheel thatincludes radial arms. Connection between a hub and rim members may beprovided by pivot pins in outer ends of these arms that have linksjournaled thereon. The links are pivotally articulated with bent levers,which are in turn pivoted on bracket arms that extend inwardly from thepart-circular plates, which are mounted on an inner periphery of a tireholding rim.

Another approach includes a disc between a wheel hub and outer rim. Forexample, U.S. Pat. No. 1,808,886 to Courtney also discloses a disc orsidewall between a wheel hub and a rim. The disc is engaged by studsthat project from the wheel hub and extends from an outer flangeobliquely to the wheel hub. The disc assists the wheel tire and rim byresisting any tendency to become displayed laterally as a result ofstresses occurring while the wheel is turning.

U.S. Pat. No. 1,979,935 to Henap discloses a hydraulic spoke wheel. Eachof the hydraulic spokes include telescoping sections in the form of anouter section and an inner section. The outer section has the studprojecting from one end. The inner section extends from the outersection and is equipped at its extended end with the stem.

U.S. Pat. No. 6,041,838 to Al-Sabah discloses a wheel that includesspokes positioned in a spaced apart relation to each other. Each of thespokes has a first end connected to a rim and a second end connected toa plate member tip of a hub plate member in an offset position from therespective radial axis thereof. The offset position of each of thespokes is further defined by each of the spokes being connected to arespective one of the plate member tips at a predetermined angle (e.g.,less than 90-degrees) from the radial axis thereof and defining anoperative offset spoke axis, which intersects the radial axis of theplate member tips at the predetermined angle.

U.S. Pat. No. 6,698,480 to Cornellier discloses shock absorbing spokeseach having a central cylindrical tube. Each tube has an interior caphaving an aperture and an exterior cap having an aperture. Each spokehas an interior piston, a rod with an aperture and a pin. The pinpivotably couples one of the spokes to the hub. Each spoke has anexterior piston, a rod with an aperture and a pin. The pin pivotablycouples one of the spokes to the rim assembly. The interior pistons andexterior pistons divide the space within each tube into an interiorchamber, an exterior chamber, and a central chamber.

Despite advances in pneumatic tire wheels, and non-pneumatic tirewheels, there is still a need for improvements in wheel technology,particularly, for large construction vehicles, or mining vehicles, forexample. The expense of wheel replacement, and the downtime experiencedduring wheel replacement may add significant expenses to theconstruction or mining projects.

SUMMARY

A wheel assembly to be coupled to a hub of a vehicle having an axis ofrotation may include an inner rim to be coupled to the hub of thevehicle and an outer rim surrounding the inner rim. The wheel assemblymay also include at least two sets of a plurality of gas springsoperatively coupled between the inner rim and the outer rim andpermitting relative movement therebetween. Each set of gas springs isseparated along said axis of rotation from every set of gas springs.Each of the gas springs has its axis bypass the axis of the inner rimand either diverge outwardly in the axial direction from said inner rimto said outer rim or is coupled to both said inner rim and said outerrim at points circumferentially separated from the points of thecoupling of any other gas spring of its set to both said inner and outerrims. The wheel assembly may further include at least one sensorconfigured to sense the relative movement between the inner and outerrims.

The wheel assembly may also include a distance measuring circuit coupledto the at least one sensor. The wheel assembly may also include awireless transmitter coupled to the distance measuring circuit, forexample.

The at least one sensor may include at least one accelerometer. The atleast one accelerometer may include an inner accelerometer carried bythe inner rim, and an outer accelerometer carried by the outer rim, forexample. The at least one accelerometer may include a three axisaccelerometer.

The at least one sensor may include a laser distance measuring sensor,for example. The at least one sensor may include an ultrasonic sensor,for example. The wheel assembly may include a temperature sensor carriedby the outer rim.

The wheel assembly may include a humidity sensor carried by the outerrim, for example. The wheel assembly may include at least one treadassembly carried by the outer rim.

The outer rim may have a diameter of at least 3.5 feet, for example.Each of the plurality of gas springs may include a double-acting gascylinder and associated piston, for example.

A method aspect is directed to a method of sensing relative movementbetween an inner rim of a wheel assembly to be coupled to a hub of avehicle and an outer rim of the wheel assembly. The outer rim surroundsthe inner rim. The wheel assembly includes a plurality of gas springsoperatively coupled between the inner rim and the outer rim andpermitting relative movement therebetween. The method may include usingat least one sensor to sense the relative movement between the inner andouter rims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a vehicle having wheel assemblies according toan embodiment.

FIG. 2 is a perspective view of a wheel assembly according to anembodiment.

FIG. 3 is another perspective view of the wheel assembly of FIG. 2.

FIG. 4 is another perspective view of the wheel assembly of FIG. 2.

FIG. 5 is a perspective view of a portion of the wheel assembly of FIG.2.

FIG. 6 is a perspective view of the inner rim, disk, and attachmentbrackets of the wheel assembly of FIG. 2.

FIG. 7 is a perspective view of a portion of a wheel assembly includingtread assemblies and a removable sidewall in accordance with anembodiment.

FIG. 8 is a perspective view of a portion of a wheel assembly inaccordance with an embodiment.

FIG. 9 is another perspective view of a portion of a wheel assembly inaccordance with an embodiment.

FIG. 10 is a perspective view of the tread member support of FIG. 9.

FIG. 11 is a perspective view of a portion of the tread assembly of FIG.9.

FIG. 12 is a perspective view of a tread member of the tread assembly ofFIG. 9.

FIG. 13 is a perspective view of an inboard clamping member of a wheelassembly according to an embodiment.

FIG. 14 is a perspective view of an outboard clamping member of a wheelassembly according to an embodiment.

FIG. 15 is a perspective view of a portion of a wheel assembly includingoutboard clamping members in accordance with an embodiment.

FIG. 16 is a cross-sectional view of a portion of an outer rim,retaining feature, and tread assembly in accordance with an embodiment.

FIG. 17 is a cross-sectional view of a portion of a tread assembly inaccordance with another embodiment.

FIG. 18 is a perspective view of a wheel assembly in accordance withanother embodiment.

FIG. 19 is a schematic diagram of the lateral stops of FIG. 18.

FIG. 20 is a schematic diagram of a portion of a wheel assemblyincluding a local controller for controlling an operating response of agas spring in accordance with an embodiment.

FIG. 21 is a schematic diagram of a portion of a wheel assemblyincluding a local controller for controlling an operating response of agas spring in accordance with another embodiment.

FIG. 22 is a perspective view of the inboard removable sidewall of thewheel assembly in accordance with an embodiment.

FIG. 23 is a perspective view of an outboard removable sidewall of awheel assembly in accordance with an embodiment.

FIG. 24 is a perspective view of a wheel assembly in accordance withanother embodiment.

FIG. 25 is a schematic diagram of a portion of a wheel assemblyincluding a sensor for measuring distance between the inner and outerrims in accordance with another embodiment.

FIG. 26 is a side cut-away view of a portion of a wheel assembly inaccordance with another embodiment.

FIG. 27 a perspective cut-away view of the portion of the wheel assemblyof FIG. 26.

FIG. 28 is a perspective view of a cover ring and flexible seal of FIG.27.

FIG. 29 is another perspective view of the cover ring and flexible sealof FIG. 27.

FIG. 30 is a perspective view of the flexible seal of FIG. 27.

FIG. 31 is a perspective view of another cover ring and flexible seal ofFIG. 27.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. Likenumbers refer to like elements throughout, and prime notation is used toindicate similar elements in alternative embodiments.

Referring initially to FIGS. 1-5, a wheel assembly 30 to be coupled to ahub 21 of a vehicle 20 includes an inner rim 31 to be coupled to the hubof the vehicle. The inner rim 31 may be coupled to the hub 21 of thevehicle 20 with fasteners through fastener receiving passageways 24within an inwardly extending flange ring 25. Illustratively, the flangering 25 is centered laterally within the inner rim 31, but may bepositioned in another arrangement based upon a desired mountingarrangement with the hub 21. Other coupling arrangements may be used tocouple the inner rim 31 to the hub 21.

The wheel assembly 30 also includes an outer rim 33 surrounding theinner rim 31. The outer rim 33 may have a diameter of at least 3.5 feet,and more particularly, at least 4 feet. Those skilled in the art willappreciate that with a diameter of at least 3.5 feet, the wheel assembly30, and more particularly, the outer rim 33 may be particularlyadvantageous for relatively large or heavy machinery, such as, forexample, earth excavation equipment and mining equipment. A typicaloverall outer diameter of such a wheel assembly may be 100 inches orgreater. The outer rim 33 may have an increased thickness portion 38along an inner circumference thereof. The increased thickness portion 38may be provided by welding a separate reinforcing ring in position or itmay be integrally formed with the outer rim 33, for example.

Referring additionally to FIG. 6, a disk 40 is coupled to the inner rim31 and defines a closeable gap 41 with adjacent interior portions of theouter rim 33. The disk 40 also includes weight-reduction openings 43therein. The weight-reduction openings 43 each illustratively have agenerally round or circular shape. The weight-reduction openings 43 mayhave another shape, such as oblong, hexagonal, and/or contoured forstress reduction, for example. Those skilled in the art will appreciatethat having a reduced weight may increase the fuel efficiency of thevehicle 20 and/or may increase the lifespan of wheel assembly 30.

The disk 40 also includes spaced apart thickened wall portions 42. Thespaced apart thickened wall portions 42 may be on both the inboard andoutboard surfaces of the disk 40. Each thickened wall portion 42 mayprovide increased strength or support as a coupling or attachment point,and/or to accept increased stresses thereat as will be described infurther detail below. The thickened wall portions 42 may be provided bywelding an additional metal body in position, for example, or they maybe integrally formed with the disk 40. Those skilled in the art willappreciate that the thickened wall portions 42 may be in the form ofsolid extensions (i.e., integrally formed with and/or a build-up of) ofthe disk 40, and/or discrete bodies, for example, that function asmechanical stiffeners.

The inner rim 31, outer rim 33, and disk 40 may be formed of a highstrength and rugged material, such as steel. As will be appreciated bythose skilled in the art other materials may also be used.

Gas springs 50 are operatively coupled between the inner rim 31 and theouter rim 33. Each gas spring 50 may be a double-acting gas spring, forexample, and include a double-acting gas cylinder 51 and an associatedpiston 52. Of course, in some embodiments, each gas spring 50 may be asingle-acting gas spring. More than one type of gas spring may be used.The gas springs 50 may be air springs and/or nitrogen springs, forexample. The gas springs 50 may include other gasses as well.

Illustratively, the gas springs 50 are arranged in pairs on oppositesides of the disk 40. More particularly, the gas springs 50 divergeoutwardly from the inner rim 31 to the outer rim 33. A respectiveattachment bracket 53 a for each gas spring 50 is coupled to arespective thickened wall portion 42 of the disk 40, for example,adjacent the inner rim 31. Each attachment bracket 53 a may include agenerally U-shaped or V-shaped base bracket that receives an end of thepiston 52 therein (e.g., between the arm of the U- or V-shaped bracket).A fastener fastens the end of the piston 52 of the gas spring 50 to thebase bracket and thus, each gas spring is coupled adjacent therespective thickened wall portion 42 of the disk 40 and adjacent theinner rim 31. A similar attachment bracket 53 b is coupled to the outerrim 33 adjacent inboard and outboard surfaces. Accordingly, the gassprings 50 are pivotably coupled between the inner and outer rims 31,33.

As will be appreciated by those skilled in the art, the gas springs 50provide a gas suspension for relative movement between the inner rim 31and the outer rim 33. The gas springs 50 have an operating stroke thepermits the disk 40 to define a mechanical stop. In other words, the gassprings 50 maintain the outer rim 33 spaced apart from the inner rim 31.However, if pressure on any gas spring 50 causes the gas spring to reachits limit under load or the gas spring fails, the disk 40 may act as amechanical stop to limit relative movement of the inner and outer rims31, 33. In other words, the disk 40 and gas springs 50 may considered asproviding a run-flat capability.

Initial charge pressures of the gas springs 50, for example, when thegas springs are in the form of double-acting gas springs, will now bedescribed, for example, with respect to initial pressures in the wheelassembly 30 when there are little or no external loads applied thereto(i.e., free-wheel). In particular, the chamber associated with thepiston-side of the cylinder 51 is typically smaller (e.g., by about 10%)than the chamber associated with the full-bore side of the cylinder.Thus, when the piston 52 is centered within the cylinder 51 so thatthere is a relatively equal stroke in tension and compression, thepiston-side chamber pressure is higher (e.g., by about 10%) than thefull-bore side chamber pressure.

Thus, while equal pressure charging of the double-acting gas cylinder 51may be convenient, it results in an offset piston 52, which, in turn,results in an offset force to be applied to assemble the gas springs 50within the wheel assembly 30. To accomplish this, the inner and outerrims 31, 33 may be temporarily fixed in a rigid jig. However, using arigid jig may make replacement of the gas springs 50 in the fieldincreasingly difficult. Thus, to address increased ease of in-fieldreplacement of the gas springs 50, weld-on rings may be coupled to theinner and outer rims 31, 33 and to turn-buckles to temporarily lock theinner and outer rims in place. A similar arrangement may be used in-shopas well, as will be appreciated by those skilled in the art.

Accordingly, the result is a pre-stressed inner rim 31 suspension to theouter rim 33. The pre-stressing may ensure that the lateral stops 44, 45(described below) are not active or under pressure. With differentcharge pressures, the suspension can be pre-compressed. While tensionsuspension and compression suspension may be considered equivalent,tension suspension may be particularly advantageous over compressionsuspension, as will be appreciated by those skilled in the art.

Another assembly technique may include applying a higher charge pressure(e.g., about 10% more) at the piston-side to center the piston 52 atabout the half-stroke position. This results in there being no initialload on the gas spring 50 at the wheel assembly 30 and facilitatesassembly without the temporary fixing within a jig. Thus, the wheelassembly 30 may be considered to be neither pre-stressed, norpre-compressed, but neutral. For example, a higher full-bore sidechamber pressure may be applied (e.g., about 10% higher) than the pistonside chamber pressure. Gas may be released from the full-bore sidechamber until the piston 52 becomes centered relative to full-stroke.Alternatively, a higher piston-side chamber pressure may be applied(e.g., about 10% higher) than the full-bore side chamber pressure.Releasing gas from the cylinder 51 may be considered easier thansurcharging, however, this may use more gas (e.g., nitrogen) than otherapproaches resulting in an increased cost.

The wheel assembly 30 also includes inboard lateral stops 44 carried byan inboard surface of the outer rim 33. More particularly, the inboardlateral stops 44 are positioned adjacent the thickened wall portion 42.The wheel assembly 30 also includes outboard lateral stops 45 carried byan outboard surface of the outer rim 33. Similarly to the inboardlateral stops 44, the outboard lateral stops 45 are adjacent thethickened wall portion 42. Each thickened wall portion 42 is positionedbetween a pair of inboard and outboard lateral stops 44, 45. The inboardand outboard lateral stops 44, 45 together with the outer rim 33 mayconceptually be considered to be in the form of an L-shaped bracket.Illustratively, the inboard and outboard lateral stops 44, 45 each has asupport plate 61 (e.g., having a rectangular shape) that is transverseto the outer rim 33 and has triangular side members 62.

As will be appreciated by those skilled in the art, the inboard andoutboard lateral stops 44, 45 cooperate to limit relative lateralmovement of the disk 40 and the outer rim 33. In other words, turning,for example, of the vehicle 20 may cause lateral movement of the disk 40relative to the outer rim 33. The inboard and outboard lateral stops 44,45 may limit the amount of lateral movement of the disk 40 relative tothe outer rim 33 to thereby maintain structural integrity of the wheelassembly 30. Of course, the inboard and outboard lateral stops 44, 45include other and/or additional components or elements that cooperate tolimit relative lateral movement of the disk 40 and the outer rim 33.

Referring now additionally to FIGS. 7-16, the wheel assembly 30illustratively includes tread assemblies 70 carried by the outer rim 33.Each tread assembly 70 includes a tread member support 71. Each treadmember support 71 may be in the form of an arcuate metal plate withopenings 69 a, 69 b therein (FIG. 10) and may couple to an outercircumference of the outer rim 33. One or more of the tread membersupports 71 may be a flat plate in other embodiments. A center one ofthe openings 69 b may receive a pin 83 therein as will be described infurther detail below. In some embodiments, the tread member support 71may not be metal, such as steel. Those skilled in the art willappreciate that given the arcuate shape of the tread member support 71,several tread assemblies 70 are coupled in end-to-end relation aroundthe outer rim 33.

A tread member 72 is coupled or bonded, for example, glued, fastened,etc., to the tread member support 71, and a clamping arrangement 73removably securing the tread member support to the outer rim 33. Theremay be more than one tread member 72 bonded to the tread member support71. The tread member 72 includes a resilient body 85 that has treadpattern 86 defined in an outer surface thereof. The resilient body 85may include rubber or other material, which may be selected based upondesired friction, traction, or other characteristics, for example, basedupon the use of the vehicle 20. The material of the tread member 72 maya metal such as steel, in other embodiments. The tread pattern 86 maysimilarly be selected based upon desired traction or othercharacteristics, for example, based upon the use of the vehicle 20.Moreover, referring briefly to FIG. 17, in another embodiment of a treadassembly 70′, each tread member 72′ and tread member support 71′ mayinclude a common material integrally formed as a monolithic unit, whichmay or may not be metal, such as steel. In other words, each treadmember 72′ and tread member support 71′ define a single unit or body ofthe same material (e.g., an all-metal tread member support and treadmember).

Further details of the clamping arrangement 73 will now be described.The clamping arrangement 73 illustratively includes inboard clampingmembers 74 coupled to the inboard side of the outer rim 33. The inboardclamping members 74 each have a first slotted recess 75 receivingadjacent portions of the tread member support 71. The inboard clampingmembers 74 are removably coupled to the inboard side of the outer rim33. The inboard clamping members 74 are illustratively arranged in anend-to-end relation and each coupled to adjacent respective portions ofthe outer rim 33. In some embodiments, the inboard clamping members 74may be fixed, for example, welded or fixedly coupled, to the inboardside of the outer rim 33 and/or a single inboard clamping member may beused.

The inboard clamping members 74 are coupled to the inboard side of theouter rim 33 by way of fasteners 79 a, for example, threaded fastenersto facilitate removal and replacement, for example, when tread members72 wear or it is desirable to replace the tread members. The threadedfasteners 79 a may extend through openings 89 in the inboard clampingmembers 74 and engage corresponding threaded openings 81 a in the outerrim 33.

The clamping arrangement 73 also illustratively includes outboardclamping members 76 coupled to the outboard side of the outer rim 33.Similar to the inboard clamping member 74, the outboard clamping members76 each has a second slotted recess 77 therein receiving adjacentportions of the tread member support 71. The outboard clamping members76 are removably coupled to the outboard side of the outer rim 33. Theoutboard clamping members 76 are illustratively arranged in anend-to-end relation and each coupled to adjacent respective portions ofthe outer rim 33. In some embodiments, a single outboard clamping member76 may be coupled to the outboard side of the outer rim 33 and extendthe circumference of the outer rim.

The outboard clamping members 76 are coupled to the outboard side of theouter rim 33 by way of fasteners, for example, threaded fasteners tofacilitate removal and replacement, for example, when tread members 72wear, or it is desirable to replace the tread members. The threadedfasteners may extend through openings 78 in the outboard clampingmembers 76 and engage corresponding threaded openings 81 b in the outerrim 33.

The tread member support 71 and adjacent portions of the outer rim 33(e.g., along the outer circumference) define a retaining featuretherebetween. The retaining feature is illustratively in the form of orincludes a pin 83 carried by the outer rim 33 and a pin-receivingopening 84 in the tread member support 71. The pin 83 and thepin-receiving opening 84 may advantageously prevent relative movementbetween the tread member support 71 and the outer rim 33, and alsofacilitate replacement (e.g., easy alignment) of the tread members 72,for example, thereby reducing downtime of the vehicle 20.

Referring now briefly to FIGS. 18 and 19, in another embodiment, theinboard and outboard lateral stops 44″, 45″ are biased toward the disk40″. More particularly, the inboard and outboard lateral stops 44″, 45″each includes an arm 46″ extending radially inward from the inboard andoutboard interior surfaces of the outer rim 33″. A transverse arm 47″ iscoupled to an end of each arm 46″. Each transverse arm 47″ carries aplug 48″ that is biased toward the disk 40″ by a biasing member 49″, forexample, a spring, such as a coil spring. Other biasing arrangements maybe used. Elements labeled 24″, 25″, 30″, 31″, 41″, 43″, 45″, 50″, 51″,52″, 70″, 76″, 79 a″, 79 b″, 85″ 86″, and 98 b″ are similar to thoserespectively numbered elements described above without double primenotation.

Referring now additionally to FIG. 20, one or more of the gas springs 50may have a controllable response. For example, the gas springs 50 mayhave either or both of a controllable gas pressure and a controllablegas volume. Any number of the gas springs 50 may have a controllableresponse. By having a controllable response, each of the gas springs 50may be operated or controlled as will be explained in further detailbelow, for example, with respect to certain operating conditions and/orenvironments. More particularly, the wheel assembly 30 may include alocal controller 87 (e.g., including a processor and/or circuitry) thatis coupled to the gas springs 50. The local controller 87 may be coupledto any number of gas springs 50. The local controller 87 may be carriedwithin the outer rim 33, for example, inside the outer rim, or by thedisk 40. The local controller 87 may be carried by other elements of thewheel assembly 30. The local controller 87 may also include respectiveactuators and/or valves to control the response of the gas springs 50and cooperate with an accumulator 91 also coupled to the gas springs toact as a pressure and/or volume storage reservoir for gas springs.

The wheel assembly 30 may also include a local sensor 88 coupled to thelocal controller 87. The local controller 87 may control (e.g., monitorand/or adjust) the operating response of the gas springs 50 based uponthe local sensor 88. For example, the local controller 87 may adjust thepressure or volume of the gas springs 50 without controlling theoperation (e.g., extend/retract) of the gas springs. The localcontroller 87 may also adjust, for example, alternatively oradditionally, the operation (e.g., extend/retract) of the gas springs50.

The local sensor 88 may be an acceleration sensor, for example, andcooperate with the local controller 87 to control the controllableresponse of the gas springs 50 based upon a sensed acceleration (e.g.,braking, turning, etc.). The local sensor 88 may be another type ofsensor, for example, a force sensor. There may be more than one localsensor 88. In some embodiments, the local controller 87 may cooperatewith the local sensor 88 to generate a notification, for example, when asensed value exceeds a threshold. The notification may be communicatewithin the vehicle 20 (e.g., in the cab) or remotely from the vehicle.In other words, the local controller 87 may cooperate with the localsensor 88 independently from or without controlling the operatingresponse of the gas springs 50.

Referring now briefly to FIG. 21, in another embodiment, a remotecontroller 92′″ may be carried remote from the wheel assembly 30, forexample, within a wheel well of the vehicle 20 or within the truck cab.The remote controller 92′″ may cooperate with the local sensor 88′″ orother sensor, for example, remote from the wheel assembly 30. The remotecontroller 92′″ may also cooperate with the local controller 87′″ toeffectuate a change in the operating response of the gas springs 50′″.Wiring from the remote controller 92′″ may extend to the localcontroller 87′″, and/or the remote controller may wirelessly communicatewith the local controller. Elements labeled 51″′, 52″′, and 91″′, aresimilar to those respectively numbered elements described above withouttriple prime notation.

Those skilled in the art will appreciate that the local controller 87controls the operating response of the gas springs 50 while the wheelassembly 30 is rolling. For example, if the vehicle 20, during motionthereof, makes a relatively sharp turn or applies the brakes, the localcontroller 87 may independently control the operating response of eachor selected ones of the gas springs 50 based upon the turn or braking(e.g., increase pressures in the gas springs of front wheel assemblies).Other motion of the vehicle 20 may cause changes in the operatingresponse, such as, for example, failure of any of the gas springs 50,debris in the tread members 72, and/or contact of the disk 40 with theouter rim 33.

Referring now additionally to FIGS. 22 and 23, the wheel assembly 30 mayinclude inboard and outboard removable sidewalls 93, 94. The inboard andoutboard removable sidewalls 93, 94 are each illustratively in the formof a round or circular cover carried by the outer rim 33. Moreparticularly, the inboard and outboard removable sidewalls 93, 94 eachhas an opening 95, 105 therein to permit, for example, coupling of thewheel assembly 30 to the hub 21. Respective flanges 103, 106 extendinwardly within the openings 95, 105. The inboard and outboard removablesidewalls 93, 94 may each be coupled to the inboard and outboard sidesof the outer rim 33 by way of fasteners 97 a, 97 b and to the inner rim31 also by way of fasteners 107 a, 107 b. The fasteners 97 a, 97 b maybe received through fastener receiving passageways along the outercircumference of each of the inboard and outboard removable sidewalls93, 94 and fasten to corresponding respective aligned threadedpassageways 98 a, 98 b in the outer rim 33. The threaded passageways 98a, 98 b in the outer rim 33 form a second, inner row of threadedpassageways, with the outer row of threaded passageways 81 a, 81 b forsecuring the clamping arrangement 73 to the outer rim with fasteners 79a (FIG. 7).

Referring now to FIG. 24, in another embodiment, the outboard removablesidewall 94″″ may have a removable inner panel 101″″ that when removed,by way of respective fasteners 102″″, permit access to inner interior ofthe wheel assembly 30″″, for example, the inner rim. Similar to theoutboard removable sidewall described above, the outboard sidewall 94″″couples by way of fasteners 97 b″″ to the outer rim inside of oradjacent the outboard clamping members 76″″ (which are secured to theouter rim also by way of fasteners 79 b″″). Elements labeled 51″″, 52″″,91″″, 70″″ and 72″″ are similar to those respectively numbered elementsdescribed above without quadruple prime notation.

As will be appreciated by those skilled in the art, the inboard andoutboard removable sidewalls 93, 94 may be particularly advantageous forreducing the amount of dust and/or debris within the interior of thewheel assembly 30, for example, between the inner and outer rims 31, 33.Accordingly, elements of the wheel assembly 30, for example, the disk 40and gas springs 50, may have increased protection against damage, forexample, from environmental elements (e.g., rocks, dust, dirt, water,etc.), and thus may have a longer service life. In some embodiments, thewheel assembly 30 may not include the inboard and outboard removablesidewalls 93, 94.

Referring now to FIG. 25, in another embodiment, sensors 188 a, 188 bsense relative movement, such as by sensing a distance between the innerrim 131 and the outer rim 133. More particularly, the sensors 188 a, 188b may be in the form of three-axis accelerometers. Of course, thesensors 188 a, 188 b may be other types of sensors, for example, laserdistance sensors, ultrasonic sensors, linear variable differentialtransformer (LVDT) sensors, and/or other contact or non-contactdisplacement sensors.

When the sensors 188 a, 188 b are in the form of three-axisaccelerometers, one of the accelerometers is carried by the inner rim131 defining an inner accelerometer, while another accelerometer iscarried by the outer rim 133 defining an outer accelerometer. The innerand outer accelerometers 188 a, 188 b are aligned by way of their axesso that relative movement of the inner and outer rims 131, 133 as asensed acceleration can be translated, for example, by way of a distancemeasuring circuit 187 coupled to the accelerometers 188 a, 188 b (e.g.,integrating each acceleration).

The sensors 188 a, 188 b may each be different from one another. Forexample, an ultrasonic sensor may be used with the inner and outeraccelerometers 188 a, 188 b to sense or measure displacement (e.g.,tangential to the inner and outer accelerometers). Of course, a laserdistance sensor may be used as an alternative to the ultrasonic sensoror in conjunction with the ultrasonic sensor and/or the inner and outeraccelerometers 188 a, 188 b. The measuring circuit 187 may be carried bythe wheel assembly, the vehicle, or remote from the vehicle.

A temperature sensor 188 c may be carried by the outer rim 133 (e.g.,within or on an inner surface of the outer rim) and coupled to themeasuring circuit 187 to sense a temperature within the wheel assembly,for example, when a cover or inboard or outboard removable sidewalls areused. A humidity sensor 188 d may alternatively or additionally becarried by the outer rim 133 (e.g., within or on an inner surface of theouter rim) and coupled to the measuring circuit 187 to sense humiditywithin the wheel assembly, for example, when a cover or inboard oroutboard removable sidewalls are used. Data representing the humidity,acceleration or distance data (e.g., raw data or processed), and/ortemperature may be remotely communicated from the wheel assembly orvehicle via a wireless transmitter 190 coupled to the measuring circuit187 for downstream processing.

Referring now to FIGS. 26-31, in another embodiment, the wheel assembly230 includes a rigid inboard cover ring 293 coupled to an inboard sideof the outer rim 233, for example, by way of fasteners 207 a. The rigidinboard cover ring 293 extends radially inward toward the inner rim 231.More particularly, the rigid inboard cover ring 293 defines a radiallyand axially extending inboard gap with the inner rim 231. A flexibleinboard seal 209 a, for example, in the form of an inboard bellows seal,is coupled between the rigid inboard cover ring 293 and the inner rim231, for example, by way of respective fasteners 208 a to couple to theinner rim (e.g., used with a clamping arrangement 212 a, such as, forexample, metal banding or other material). The flexible inboard seal 209a closes the radially and axially extending inboard gap and permitsrelative movement of the inner rim 231 and the outer rim 233.Illustratively, the inboard bellows seal 209 a has a Z-shapedcross-section. The flexible inboard seal 209 a may be a different kindof flexible seal, for example, and may have a different shapedcross-section. The flexible inboard seal 209 a may include rubber and/oran elastomeric material. The flexible inboard seal 209 a may includeother and/or additional materials.

The wheel assembly 230 also includes a rigid outboard cover ring 294coupled to an outboard side of the outer rim 233, for example by way offasteners 207 b. The rigid outboard cover ring 294 extends radiallyinward toward the inner rim 231. More particularly, the rigid outboardcover ring 294 defines a radially and axially extending outboard gapwith the inner rim 231. A flexible outboard seal 209 b, for example, inthe form of an outboard bellows seal, is coupled between the rigidoutboard cover ring 294 and the inner rim 231, for example, by way ofrespective fasteners 208 b (and respective clamping arrangement 212 b,for example). The flexible inboard seal 209 b closes the radially andaxially extending outboard gap and permits relative movement of theinner rim 231 and the outer rim 233. Illustratively, the outboardbellows seal 209 a has a Z-shaped cross-section. The flexible outboardseal 209 b may be a different kind of flexible seal, for example, andmay have a different shaped cross-section.

Still further, a respective pleated cover 210 (e.g., bellows), iscoupled to each of the gas springs 250. In particular, the pleatedcovers 210 cover the piston so that dust, dirt, and/or debris may bekept from the piston (FIG. 26). A reduced amount of dust, dirt, and/ordebris in contact with the piston may increase the operational lifespanof the gas springs 250, as will be appreciated by those skilled in theart.

The flexible outboard seal 209 b may include rubber and/or anelastomeric material. The flexible outboard seal 209 b may include otherand/or additional materials. A rigid outboard cover ring 294 and aflexible outboard seal 209 b may not be used in some embodiments.Elements labeled 224, 225, 240, 241, 242, 243, 244, 245, 262, 281 a and283 are similar to respective elements labeled 24, 25, 40, 41, 42, 43,44, 45, 62, 81 a and 83 (i.e. decremented by 200) described above.

Referring now particularly to FIG. 31, similar to the embodimentsdescribed above with respect to FIGS. 22-24, a rigid removable insetpanel or inner panel 201 may be carried within the rigid outboard coverring 294 (e.g., secured to the wheel assembly by way of fasteners 297 b)so that when removed, by way of respective fasteners 202, permits accessto inner interior of the wheel assembly 230, for example, the inner rim.Access ports or removable covers 211 a are spaced apart within the rigidoutboard cover ring 294. The removable covers 211 a may be clearacrylic, for example, to permit visual inspection within the wheelassembly without removing the rigid removable inset panel 201 and/or topermit ease of access to sensors, controller, and/or other circuitry,for example, as described above. A similar arrangement including theaccess ports or removable covers 211 b may be used as the rigid inboardcover ring 294, for example, as described above (FIGS. 26-27). Theaccess ports 211 a, 211 b may be not used in all embodiments.

The embodiments of the wheel assembly 30 described herein may beparticularly advantageous with respect to a conventional pneumatic tire,for example, particularly on a relatively large vehicle (e.g., heavymachinery). A conventional pneumatic tire, for example, for heavymachinery has a relatively high cost and, in some environments, may havea relatively short usage life. Moreover, particularly with heavymachinery, a failure of a conventional tire may cause be associated withan increased chance of damage to the heavy machinery. Even stillfurther, a failure of a conventional tire may cause the vehicle 20 to beinoperable or out of service for a relatively long time period, thusresulting in a financial loss and loss of productivity, particularly forcertain types of vehicles or heavy machinery that operate around theclock.

The wheel assembly 30 may address these shortcomings of a conventionaltire. More particularly, the wheel assembly 30 may have a loweroperational cost with increased performance (e.g., by way of thecontrollable operating response of the gas springs 50). Additionally,the wheel assembly 30 may be field serviceable, meaning that treadmembers 72 may be replaced in the field. Repairs, for example, in thecase of failed gas springs 50, may also be repaired in the field.

A method aspect is directed to a method of making a wheel assembly 30 tobe coupled to a hub 21 of a vehicle 20. The method includes operativelycoupling a plurality of gas springs 50 between an inner rim 31 to becoupled to the hub 21 of the vehicle 20 and an outer rim 33 surroundingthe inner rim. The method also includes mounting a plurality of treadassemblies 70 to the outer rim 33. Each tread assembly 70 may be mountedby bonding at least one tread member 72 to a tread member support 71 andpositioning a clamping arrangement 73 to removably secure the treadmember support to the outer rim 33.

Another method aspect is directed to a method of making wheel assembly30 to be coupled to a hub 21 of a vehicle 20. The method includesoperatively coupling a plurality of gas springs 50 between an inner rim31 to be coupled to the hub 21 of the vehicle 20 and an outer rim 33surrounding the inner rim 31 to provide a gas suspension for relativemovement between the inner rim and the outer rim. The method alsoincludes coupling a disk 40 to the inner rim 31 that defines a closeablegap 41 with adjacent interior portions of the outer rim 33 to define amechanical stop to limit relative movement of the inner rim and outerrim.

Another method aspect is directed to a method of making a wheel assembly30 to be coupled to a hub 21 of a vehicle 20. The method includesoperatively coupling a plurality of gas springs 50 operatively betweenan inner rim 31 to be coupled to the hub 21 of a vehicle 20 and an outerrim 33 surrounding the inner rim to provide a gas suspension forrelative movement between the inner rim and the outer rim. The methodalso includes coupling a disk 40 coupled to the inner rim 31 anddefining a closeable gap 41 with adjacent interior portions of the outerrim 33. The method may further include positioning a plurality ofinboard lateral stops 44 carried by an inboard interior surface of theouter rim 33, and positioning plurality of outboard lateral stops 45carried by outboard interior surface of the outer rim so that theplurality of inboard lateral stops and plurality of outboard lateralstops cooperate to limit relative lateral movement of the disk 40 andthe outer rim.

Another method aspect is directed to a method of making a wheel assembly30 to be coupled to a hub 21 of a vehicle 20. The method includesoperatively coupling a plurality of gas springs 50 between an inner rim31 to be coupled to the hub 21 of the vehicle 20 and an outer rim 33surrounding the inner rim. At least one gas spring 50 from among theplurality thereof has a controllable operating response. The method alsoincludes coupling a local controller 87 to the at least one gas spring50 to control the operating response of the at least one gas spring.

Another related method aspect is directed to a method of operating awheel assembly 30 to be coupled to a hub 21 of a vehicle 20. The wheelassembly 30 includes an inner rim 31 to be coupled to the hub 21 of thevehicle 20, an outer rim 33 surrounding the inner rim, and a pluralityof gas springs 50 operatively coupled between the inner rim and theouter rim. At least one gas spring 50 from among the plurality thereofhas a controllable operating response. The method includes operating alocal controller 87 coupled to the at least one gas spring 50 to controlthe operating response of the at least one gas spring.

Another method aspect is directed to a method of sensing relativemovement, e.g. a distance, between an inner rim 131 of a wheel assembly30 to be coupled to a hub 21 of a vehicle 20 and an outer rim 133 of thewheel assembly. The inner rim 131 is to be coupled to the hub 21 of avehicle 20 and the outer rim 133 surrounding the inner rim. The wheelassembly 30 includes a plurality of gas springs 50 operatively coupledbetween the inner rim 131 and the outer rim 133 and permitting relativemovement therebetween. The method includes using at least one sensor 188a, 188 b to sense the relative movement between the inner and outer rims131, 133 during operation or rolling of the wheel assembly.

Another method aspect is directed to a method of making a wheel assembly30 to be coupled to a hub 21 of a vehicle 20. The method includescoupling an inner rim 231 to be to the hub 21 of the vehicle 20 andpositioning an outer rim 233 surrounding the inner rim. The method alsoincludes operatively coupling a plurality of gas springs 50 between theinner rim 231 and the outer rim 233 to permit relative movementtherebetween. The method further includes coupling a rigid inboard coverring 293 to an inboard side of the outer rim 233 and extending radiallyinward toward the inner rim 231 and coupling a flexible inboard seal 209a between the rigid inboard cover ring and the inner rim.

While several embodiments have been described herein, those skilled inthe art will appreciate that any one or more elements from any one ormore embodiments may be used in conjunction with any one or moreelements from any other embodiment or embodiments. Moreover, whilereference is made herein to inner and outer, those skilled in the artwill appreciate that in many embodiments, elements described withrespect to inner may be used as outer and vice versa, and/or thoseelements described as being inner may be used with elements described asbeing outer and vice versa.

Many modifications and other embodiments of the invention will come tothe mind of one skilled in the art having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Therefore, it is understood that the invention is not to be limited tothe specific embodiments disclosed, and that modifications andembodiments are intended to be included within the scope of the appendedclaims.

That which is claimed is:
 1. A wheel assembly to be coupled to a hub ofa vehicle, the wheel assembly defining a non-pneumatic tire for thevehicle and comprising: an inner rim to be coupled to the hub of thevehicle; an outer rim surrounding the hub; a plurality of gas springsoperatively coupled between said inner rim and said outer rim andpermitting relative movement therebetween; at least one sensorconfigured to sense the relative movement between said inner rim andsaid outer rim; a humidity sensor carried by an inner surface of saidouter rim; an inboard sidewall coupled between an inboard side of saidinner rim and an inboard side of said outer rim; and an outboardsidewall coupled between an outboard side of said inner rim and anoutboard side of said outer rim.
 2. The wheel assembly of claim 1,comprising a distance measuring circuit coupled to said at least onesensor.
 3. The wheel assembly of claim 2, comprising a wirelesstransmitter coupled to said distance measuring circuit.
 4. The wheelassembly of claim 1, wherein said at least one sensor comprises at leastone accelerometer.
 5. The wheel assembly of claim 4, wherein said atleast one accelerometer comprises an inner accelerometer carried by saidinner rim, and an outer accelerometer carried by said outer rim.
 6. Thewheel assembly of claim 4, wherein said at least one accelerometercomprises a three axis accelerometer.
 7. The wheel assembly of claim 1,wherein said at least one sensor comprises a laser distance measuringsensor.
 8. The wheel assembly of claim 1, wherein said at least onesensor comprises an ultrasonic sensor.
 9. The wheel assembly of claim 1,comprising at least one tread assembly carried by said outer rim. 10.The wheel assembly of claim 1, wherein said outer rim has a diameter ofat least 3.5 feet.
 11. The wheel assembly of claim 1, wherein each ofsaid plurality of gas springs comprises a double-acting gas cylinder andassociated piston.
 12. A wheel assembly to be coupled to a hub of avehicle, the wheel assembly defining a non-pneumatic tire for thevehicle and comprising: an inner rim to be coupled to the hub of thevehicle; an outer rim surrounding the hub; a plurality of gas springsoperatively coupled between said inner rim and said outer rim andpermitting relative movement therebetween; at least one sensorconfigured to sense the relative movement between said inner rim andsaid outer rim; a humidity sensor carried by an inner surface of saidouter rim; a temperature sensor carried by the inner surface of theouter rim; an inboard sidewall coupled between an inboard side of saidinner rim and an inboard side of said outer rim; and an outboardsidewall coupled between an outboard side of said inner rim and anoutboard side of said outer rim.
 13. The wheel assembly of claim 12,comprising a distance measuring circuit coupled to said at least oneaccelerometer.
 14. The wheel assembly of claim 13, comprising a wirelesstransmitter coupled to said distance measuring circuit.
 15. The wheelassembly of claim 12, wherein said at least one sensor comprises atleast one accelerometer.
 16. The wheel assembly of claim 15, whereinsaid at least one accelerometer comprises an inner accelerometer carriedby said inner rim, and an outer accelerometer carried by said outer rim.17. The wheel assembly of claim 15, wherein said at least oneaccelerometer comprises a three axis accelerometer.
 18. The wheelassembly of claim 12, further comprising a tread assembly carried bysaid outer rim.
 19. A method of sensing relative movement between aninner rim of a wheel assembly to be coupled to a hub of a vehicle and anouter rim of the wheel assembly, the outer rim surrounding the innerrim, the wheel assembly defining a non-pneumatic tire and comprising aplurality of gas springs operatively coupled between the inner and outerrims and permitting relative movement therebetween, an inboard sidewallcoupled between an inboard side of the inner rim and an inboard side ofthe outer rim, and an outboard sidewall coupled between an outboard sideof the inner rim and an outboard side of the outer rim, the methodcomprising: using at least one sensor to sense the relative movementbetween the inner rim and the outer rim; and using a humidity sensorcarried by an inner surface to sense a humidity within the wheelassembly.
 20. The method of claim 19, comprising using a distancemeasuring circuit coupled to the at least one sensor to sense thedistance between the inner rim and the outer rim.
 21. The method ofclaim 20, comprising using a wireless transmitter coupled to thedistance measuring circuit to wirelessly communicate data representativeof the distance between the inner and outer rims.
 22. The method ofclaim 19, wherein the at least one sensor comprises at least oneaccelerometer.